PROJECT OVERVIEW
NES Fircroft supplied eight highly qualified offshore wind turbine installation and commissioning quality inspectors to a turbine manufacturer, for the installation and commissioning of HALIADE-X wind turbines.
The quality inspectors were deployed across two vessels: the Wind Turbine Installation Vessel (WIV) and the Service Operations Vessel (SOV). The project involved the installation and commissioning of a total of 62 HALIADE-X wind turbines. NES Fircroft’s quality inspectors worked closely with the installation contractor and the commissioning company, covering both day and night shifts on a three-week onshore/offshore rotation schedule.
Scope of Work
Number of Inspectors: 8 Quality Inspectors
Vessel Assignment:
- 4 inspectors based on the Wind Turbine Installation Vessel (WIV)
- 4 inspectors based on the Service Operations Vessel (SOV)
Shift Coverage: Day shift and night shift
Rotation Schedule: Three-week onshore/offshore rotation
Collaboration: Inspectors worked in close coordination with GWS (Global Wind Service) and Eniprev
WIND TURBINE INSTALLATION VESSEL (WIV)
The WIV was responsible for the installation of offshore wind turbines and the completion of essential commissioning tasks. The NES Fircroft quality inspectors on the WIV were responsible for the following tasks on behalf of the client.
Bolt Tensioning
- Checking and acceptance of bolt tensioning of three tower sections
- Acceptance of the nacelle installation and bolt tensioning
Wind Turbine Blade Installation
- Checking and acceptance of wind turbine blade bolt tensioning
- Checking and acceptance of the blade pitch box and final blade pitch adjustments
Shaft Monitoring Systems
Checking and acceptance of the installation of shaft “brushes,” which are essential for monitoring the condition of turbine shafts during operation
Calibration of Measurement Devices
- Calibration and verification of bolt tensioning measurement devices
- Inspectors trained in the operation of ITH tensioning equipment and handheld torque measurement devices
Cable Installation
- Ensuring all cable installations were completed according to requirements
- Checking cable continuity measurements, inspecting junction box terminations, and verifying equipment and instrument terminations
- Ensuring correct cable routing and attachments
Equipment Phase Checks
- Performing phase checks on equipment to ensure correct operation
Navigation Light Installation
- Checking and acceptance of navigation light installation and their commissioning in accordance with USCG guidance
Punch Lists and Non-Conformance Reporting
- Issuing Punch Lists for incomplete or non-conforming work
- Reporting non-conformances using Smart Sheet and Quality Sheet
Final Walk Down and Punch List Closeout
- Conducting the final walkdown of the installation site
- Issuing the final Punch List and ensuring follow-up on punch list closeouts
Services Operations Vessel
The SOV was responsible for carrying out the pre-commissioning checks and, where possible, the commissioning of the wind turbine installation work carried out by the WIV. The NESF quality inspectors on the SOV were tasked with supporting various pre-commissioning and commissioning activities, including:
Recording and Documenting
- Recording and documenting the wind turbine punch lists
- Issuing non-conformance reports
- Issuing corrective action work orders
- Updating project databases using Smart Sheet (defects) and Quality Sheet (punch lists)
- Assisting the client’s system specialists in updating client proprietary software
Daily Status Meetings
- Attending daily status meetings
- Coordinating with the onshore-based client head of project quality
Walkdown and Inspection
Walkdown and Inspection
- Conducting walkdowns (punch listing) of installation work by internal platform level
- Verifying safety equipment, lifeline installations, and anchoring points
- Inspecting switchgear installation (loose connections), cleanliness, wire routing, and securing
- Checking escape route markings
- Verifying proper fitting of hatches
- Checking installation tolerances
- Inspecting cooling system and hydraulic lube oil levels
Compliance
- Inspections were carried out in accordance with OSHA and USCG requirements and the client’s quality inspection and testing plan (ITP)
DELIVERABLES
- Daily and Shift Reports: Submission of daily reports detailing the progress, issues, and resolutions during the installation and commissioning process.
- Final Inspection Reports: Comprehensive reports summarizing the inspections, findings, and final acceptance of the installations.
- Non-Conformance Reports (NCRs): Detailed reports on any non-conformances identified during the inspection process, including corrective actions taken.
- Punch Lists: Detailed Punch Lists identifying incomplete or non-conforming work, with follow-up documentation on closeouts.
Timeline
The deployment schedule, rotation, and key milestones were managed and tracked according to the project timeline agreed upon with the client.
Responsibilities
NESF ensured all inspections and quality checks were conducted according to the client’s ITP standards and industry regulations.
Health, Safety & Environmental Compliance
All activities performed by NES Fircroft inspectors complied with the client’s and OSHA’s health, safety, and environmental policies,as well as all relevant maritime and offshore regulations.
Quality Assurance
NES Fircroft ensured that all inspection and commissioning activities met the highest quality standards, with rigorous adherence to the client’s specifications and industry best practices.
Reporting and Communication
Regular communication between NES Fircroft, the client, and GWS to ensure alignment on project progress, issues, and resolutions.